Chevrolet Sonic manuals

Chevrolet Sonic Repair Manual: Intake Manifold Replacement (LDE)

Removal Procedure
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  2. Remove the throttle body assembly. Refer to Throttle Body Assembly Replacement.


  3. Disconnect wiring harness plug.
  4. Disconnect the pipes from the evaporative emission canister purge solenoid valve (1).
  5. Remove the evaporative emission canister purge solenoid valve (1) and the rubber mounting from the intake manifold (2).
  6. Disconnect and reposition the electrical connectors as necessary.
  7. Remove the fuel injector rail. Refer to Fuel Injector Replacement.
  8. Remove the manifold absolute pressure sensor. Refer to Manifold Absolute Pressure Sensor Replacement.

  9. :1
  10. Remove the evaporative emission canister purge solenoid valve bracket bolts (1).
  11. Remove the evaporative emission canister purge solenoid valve bracket (2).

  12. Disconnect the booster vacuum pipe (1) from the intake manifold.
  13. Remove the front wheel drive shaft right side. Refer to Front Wheel Drive Shaft Replacement.
  14. Remove the starter. Refer to Starter Replacement.
  15. Remove the generator. Refer to Generator Replacement.


  16. Remove and DISCARD the transmission rear mount to bracket through bolt (1).

  17. Remove the intake manifold bolts (1).
  18. Remove the intake manifold (2).
  19. Clean and inspect the intake manifold. Refer to Intake Manifold Cleaning and Inspection.
Installation Procedure
  1. Clean the sealing surfaces.
  2. Install the NEW gasket.

  3. Caution:

    Refer to Fastener Caution.

  4. Install the intake manifold (2) and the 7 intake manifold bolts (1) and tighten to 20 Y (15 lb ft)

    .



  5. Install the NEW transmission rear mount to bracket through bolt (1) and tighten to 80 Y (59 lb ft) plus 45-60 degrees

    .

  6. Install the generator. Refer to Generator Replacement.
  7. Install the starter. Refer to Starter Replacement.
  8. Install the front wheel drive shaft right side. Refer to Front Wheel Drive Shaft Replacement.


  9. Connect the booster vacuum pipe (1) to the intake manifold.
  10. Install the manifold absolute pressure sensor. Refer to Manifold Absolute Pressure Sensor Replacement.

  11. :1
  12. Install the evaporative emission canister purge solenoid valve bracket (2).
  13. Install the evaporative emission canister purge solenoid valve bracket bolts (1) and tighten to 8 Y (71 lb in)

    .

  14. Connect the electrical connectors as necessary.
  15. Install the fuel injector rail. Refer to Fuel Injector Replacement.


  16. Install the evaporative emission canister purge solenoid valve (1) and the rubber mounting to the intake manifold (2).
  17. Connect the pipes to the evaporative emission canister purge solenoid valve (1).
  18. Connect wiring harness as necessary.
  19. Install the throttle body assembly. Refer to Throttle Body Assembly Replacement.
  20. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
Intake Manifold Replacement
Special Tools EN-34730?E1 Pressure Tester EN-6015 Closure Plugs For equivalent regional tools, refer to Special Tools Removal Procedure Disconnect the battery negative cable. R ...

Intake Manifold Replacement (LUW)
Removal Procedure Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection. Remove the throttle body assembly. Refer to Throttle Body As ...

Other materials:

Battery Disconnect Warning
Warning: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in c ...

Turbocharger Assemble
Caution: Refer to Fastener Caution. Install the NEW quick fitting connector (2) and a NEW seal ring (1) to the turbocharger and tighten to 20 Y (15 lb ft). Inspect the turbocharger coolant pipes for ridges and damage. Install the tur ...

Manual Shift Shaft Seal Removal
Manual Shift Shaft Seal Removal Callout Component Name 1 Manual Shift Shaft Seal Note: Use the DT-45201 seal remover to remove the seal to prevent damage to the case surface. Special Tools DT-452 ...

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